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GUIDE
Your trusted partner for
Plastic Injection Moulding
Description
Consistent Defects
Irregular Defects
Distortion
Flash
Sink Marks
Short Mouldings
10
11
Burn Marks
11
Gas Traps
12
Black Specks
13
Ejector Marks
14
Nozzle Drool
15
Cold Slugs
16
Delamination / Splay
17
Discolouration
18
Inconsistent Melts
19
Gloss Differences
20
Jetting
21
22
Tiger Lines
23
Appendix 1
Your trusted partner for
Plastic Injection Moulding
CONSISTENT DEFECTS
This will usually indicate a problem in the injection nozzle, the hot
runner system or shape and design of the cold runner feed and
gate.
1. Investigate the moulding process conditions .
2. Investigate the Product Design.
IRREGULAR DEFECTS
Look at compounding factors such as low melt temperature,
backpressure, screw speed and retraction can also be important
here.
1. Defects covering a large area.
2. Often already visible on the sprue.
3. Check for decomposition of the polymer melt.
Solutions:
to
Solutions
1.
4.
2.
3.
5.
6.
7.
8.
9.
Example of
Flash
Sink Marks
Sink Marks occur on the A
surface of the moulding or
bubbles
through
slightly
thicker regions of the part.
A Surface
Solutions
Solutions
Solutions
1. Decrease injection
pressure.
2. Decrease the holding
pressure.
3. Minimize cushion.
4. Check for undercuts or
insufficient draft particularly
on textured surfaces.
5. Stuck on the Fixed Half:
6. Increase close time.
7. Decrease Moving half
temperature.
8. Stuck on the Moving Half:
9. Decrease close time.
10. Decrease Fixed half
temperature.
11. Polish Surface of the Tool.
12. Vapour Blast the surface of
the Tool.
1.
2.
3.
4.
5.
6.
7.
Solutions
1.
Gas Traps
Gas Traps or Air Traps occur when
the melt races around a local area,
the resultant gas trap can range
from incomplete filling to burning
due to the Diesel effect.
2.
3.
4.
Black Specs
Solutions
Black Specks
Ejector Marks
After ejection from the mould,
ejector pins have clearly left
visible marks on the surface of
the moulding in the form of
depressions, differences in
gloss or stress whitening.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Solutions
Nozzle Drool
Nozzle Drool String might
remain from previous shot
transferred into the new shot
and usually evident on the
surface of the moulding.
1. Reduce nozzle
temperature.
2. Reduce material
temperature.
3. Minimize cushion.
4. Delay sprue break time.
5. Decrease mould open time.
6. Use nozzle with smaller
diameter orifice.
7. Use decompression to hold
the melt back from the
nozzle.
8. Ensure that the material has
been correctly dried.
9. Consider Fitting Shut off
Nozzle or Tip.
Solutions
Cold Slugs
A small amount of melt
solidifies at the gate point
before the start of injection
and is pushed into the mould
cavity via the melt stream.
Evidence of a cold slug
normally occurs close to the
injection point.
Solutions
Delamination/Splay
Delamination refers to the
splitting open/peeling off of the
surface or separation of the
compound components and is
usually due to excessive
shearing of the melt breaking
down the polymer structure.
Splay is similar but the
delamination appears like
radial cracks or lines on the
moulding surface.
Delamination
6. Consider adding a
hemispherical gate well
opposite the gate to
reduce shear and stress
in the immediate area.
Discolouration
Solutions
Inconsistent Melts
Inconsistent
pigmentation.
melting
Solutions:
and
1.
2.
3.
4.
5.
Gloss Differences
Solutions
1.
2.
3.
4.
5.
6.
7.
Experiment with
increasing the mould
temperature.
Increase the melt
temperature.
Increase the hold
pressure.
Check and optimise hold
time.
Optimise the point at
which the changeover to
hold pressure is made.
Optimise the injection
rate.
Improve consistency of
the melt by increasing the
back-pressure and / or
screw speed.
Jetting
Solutions
Example of Jetting
Moisture/Silver Streaks
Silver/Moisture streaks are
distinct streaks, usually radiating
from the gate and are often
caused by excess moisture, air
introduced or degradation
during plasticisation of the melt
in the barrel of the machine.
Many plastics absorb moisture
from the atmosphere; how much
they absorb depends on the
type of resin. Moisture in the
granules, even if it is only
surface condensation, can
cause problems in parts
including, poor surface finish,
processing issues, increased
flash or loss of mechanical
properties such as impact and
tensile strength in some
materials.
Solutions
1. Increase back pressure.
2. Decrease melt temperature.
3. Check the mould cooling
circuit for leaks onto the
mould face.
4. Check the packaging of the
plastic granules for damage.
5. Check the moisture content of
the granules.
6. Ensure pre-drying at
recommended temperature
and time.
7. Reduce the quantity of
granules held in the feed
hopper.
8. Check raw material storage
conditions.
Solutions
Tiger Lines
Tiger lines are radial shadows
on the surface of the moulding.
Caused by pulsating polymer
melt flow.
Some
compounds
naturally
exhibit a slip stick flow effect that
can show up as tiger stripes, but
a common cause is worn screw,
barrel or check ring.
APPENDIX 1